Sorter control

ABSTRACT

A reproduction system incorporating a processor for making copies, a document handler for automatically feeding in seriatim documents to be copied to the processor and thereafter returning the documents to the document supply tray for either removal or recycling, and a sorter for either stacking or collating the copies. The sorter includes a procession of copy receiving trays and gates to route the copies into selected ones of the sorter trays. The sorter is arranged to either collate or stack, and is pre-set so that when the sorter bins are empty, the copies are automatically routed to a predetermined one of the sorter bins.

1451 Mar. 18, 1975 SORTER CONTROL [75] Inventors: William P. Kulruclra,Webster;

Thomas Acquaviva, Penfield, both of NY.

[73] Assignee: Xerox Corporation, Stamford,

Conn.

[22] Filed: Dec. 4, 1972 [21] Appl. No.: 312,143

' i111Illll]llllllllllllllllllllllll lllll I11 IIIIIMMMHHIIIIIHE? lllllllllllll IIIIIIIIIIIIIIIFII 2/1972 Schulz et a1. 271/64 x 1/1973 Baker eta1. 271/173 Primary Examiner-Richard A. Schacher AssistantExaminer-Bruce H. Stoner, Jr.

[57] ABSTRACT A reproduction system incorporating a processor for makingcopies, a document handler for automatically feeding in seriatimdocuments to be copied to the processor and thereafter returning thedocuments to the document supply tray for either removal or recycling,and a sorter for either stacking or collating the copies. The sorterincludes a procession of copy receiving trays and gates to route thecopies into selected ones of the sorter trays. The sorter is arranged toeither collate or stack, and is pre-set so that when the sorter bins areempty, the copies are automatically routed to a predetermined one of thesorter bins.

3 Claims, 4 Drawing Figures PATEME HAM aims \QQ Q She SORTER- CONTROLThis invention relates to a reproduction system, and more particularly,to an improved sorter for use with reproduction systems.

In reproduction systems incorporating both a high speed copy processorand copy sorter, the processor and sorter may cooperate to providecopies stacked page by page or collated in book fashion. Rather thanlimit the sorter to either stacking or collating modes, it isadvantageous to use the sorter for both types of sort- .ing. Incontradistinction, one known system employs the sorter for collatingpurposes only and provides a separate tray in which copies are depositedduring stacking.

It is a principal object of the present invention to provide a new andimproved reproduction system.

It is a further object of the present invention to provide an improvedsorter for use in reproduction systems.

It is an object of the present invention to provide a control formulti-bin sorters effective to route copies to a predetermined one ofthe bins when the bins are empty.

It is an object of the present invention to provide an improved sorterdesigned to selectively stack or collate copies.

This invention relates to a reproduction system comprising, incombination; a processor for making copies of original documents; asorter for sorting the copies into desired orientation, the sorterhaving a series of copy receiving trays arranged in procession startingwith a first tray; and programming means for selectively programming thesystem so that the processor and sorter cooperate to provide a collatedset of copies in a series of the sorter trays used starting with thefirst sorter tray or to provide stacks of copies of each document inindividual sorter trays with the first stack of document copies in thefirst sorter tray.

These and other objects of the invention will be apparent from theensuing description and drawings in which:

FIG. 1 is a perspective view of the reproduction system incorporatingthe improved control of the present invention;

FIG. 2 is a side sectional view showing details of the processor platencover and transport;

FIG. 3 is a side sectional view of the reproduction system sorter; and

FIG. 4 is a diagram showing schematically the control circuit for thereproduction system of FIG. 1 including the sorter control of thepresent invention.

For a general understanding of reproduction apparatus with which thepresent invention may be incorporated, reference is made to FIG. 1wherein various components of a typical electrostatic printer system areillustrated. The printer system is of the xerog'raphic type and isgenerally designated with the reference numeral 10. As in allxerographic systems, a light image of an original to be reproduced isprojected onto the sensitized surface of a xerographic plate to form anelectrostatic latent image. Thereafter, the latent image is developedwith toner material to form a xerographic powder image corresponding tothe latent image on the plate surface. The powder image is thenelectrostatically transferred to a record material such as a sheet orweb of paper or the like to which it may be fused by a fusing devicewhereby the powder image is caused permanently to adhere to the surfaceof the record material.

The xerographic processor indicated by the reference numeral 11 isarranged as a self-contained unit having all of its processing stationslocated in a unitary enclosure or cabinet. The printer system includesan exposure station at which a light radiation pattern of a document tobe reproduced and positioned on a glass platen 12 is projected onto aphotoconductive surface in the form of a xerographic belt 13. Thedocument is transported by a recirculating document handler 15 fromsupply stack 17 on tray 19 to the platen for exposure and then returnedto the supply stack on completion of the exposure. This procedure isrepeated until the entire stack has been copied at which time the cyclemay be repeated or the documents removed.

As best seen in FIG. 2, document handler 15 includes a belt-type platentransport 14 disposed atop platen 12 for moving documents into and outof copying position on platen 12. Transport 14 is operatively supportedon spaced rollers 15, 16, roller 16 being driven by suitable means (notshown) to operate transport 14 forward and backward as required. Theentire transport 14 is swingable about the axis of rear dlrive roller topermit transport 14 to be raised for access to platen l2. Similarly,platen cover 9, which overlays transport 14, is supported for swingingmovement about the axis of pin 8 to permit cover 9 to be swung open.This is normally done when it is desired to copy documents manually andto provide service accessibility to the parts.

Suitable illumination means such as flash lamps 18 are provided. Thelight image is projected by first mirror 20, projection lens 21, andsecond mirror 23 onto the xerographic belt 13 at the focal plane for thelens 21 at a position indicated by the dotted line 25.

As an interface structure and for unobstructive optical projections, theside of the cabinet is formed with an enlarged rectangular opening topermit the projection of image light rays from the lens 21 to the mirror23. Similarly, the cabinet forming the document plane is formed with acorresponding rectangular opening that mates with the opening in theprinter cabinet when the two cabinets are operatively joined togetherfor copying purposes. Suitable light tight gaskets may be utilizedadjacent the exterior of each opening in the cabinets in order tominimize the leakage of unwanted extraneous light.

The xerographic belt 13 is mounted for movement around three parallelarranged rollers 27 suitably mounted in the frame processor 11. Belt 13is driven by a suitable motor (not shown) at an appropriate speed. Theexposure of the belt to the light image from the document selectivelydischarges the photoconductive layer to provide an electrostatic latentimage corresponding to the light image projected from the document.

Movement of belt 13 takes the electrostatic latent image past developerapparatus 29 where the electrostatic latent image is developed by asuitable toner in conformance with the charge pattern thereon. Afterdevelopment, the powder image moves to an image transfer station whereatrecord material, i.e. paper or sheets from either main or auxiliarysheet supply 30, 31, respectively, is brought into image transferrelationship with belt 13 to receive the powder image therefrom.Suitable roll type feeder devices 33 are provided for feeding one sheetat a time from supply stacks 30, 31, the sheet being moved insynchronism with belt 13 during transfer of the developed image andregistered with the image on belt 13 by suitable means (not shown).

After transfer, sheets are conveyed to a suitable fuser 34 which fusesor fixes the powder thereon. After fusing, the sheets may be depositedin either copy tray 35 or conveyed to sorter 32, a suitable gate (notshown) being provided to selectively route the sheets to either tray 35or sorter 32.

Further details of the processing devices and stations in the printersystem may be found in US. Pat. Nos. 3,661,452, issued May 9, 1972, andNo. 3,597,071, issued July 27, 1971, which are commonly assigned withthe present invention.

Referring to FIG. 3, sorter 32 comprises a base frame 51 which supportsupper and lower sorter bins 53, 55, respectively. Lower bin 55 includesa unitary framework which defines a series of trays 59 which receivecopy sheets in a downward direction. Similarly, upper bin 53 has aunitary framework which defines a series of trays 59 for receiving copysheets.

Sheets enter sorter 32 through an opening formed in the frame of thelower sorting assembly 55. The sheets pass through guides 63 to a pairof pinch rolls 65 and 67 which direct the sheets to either horizontaltransport '69 or to vertical transport 129 depending on the position ofa deflector 135. Transport 69 is made up of a plurality of horizontalbelts 71 driven by motor 153 (FIG. 4). Belts 71 are above the sheet pathand free wheeling rollers 73 are positioned below the sheet path. Aboverollers 73 are rollers 74 which are positioned within belts 71 and arespring loaded downward to ensure proper traction between the belts andsheets being transported.

Sheets traveling on the horizontal belts 71 are deflected downward intoan appropriate tray by fingers or gates 76. The position of each gate iscontrolled by an individual solenoid 37 in accordance with the solenoidcontrol logic (FIG. 4). As will appear, operation of solenoids 37 isnormally controlled by passage of a sheet downwardly from horizontaltransport 69 into one of the trays 59 which causes the breaking andmaking of the light beam established between light source 78 and asuitable optical sensor such as phototransistor 80. The ensuing signalpulse is relied upon to trigger the next gate solenoid whilede-energizing the previous gate solenoid. This results in the gate forthe next tray 59 being moved into intercepting position, that isdepressed, while the gate to the preceding tray is moved out ofintercepting position, that is raised, suitable spring means (not shown)being provided to bias gates 76 in a raised position.

The upper sorting bin 53 includes a similar horizontal transport 115made up of a plurality of horizontal belts 117 driven by a motor 167which moves above the sheet path and free wheeling rollers 119positioned below the sheet path. Above rollers 119 are rollers 121 whichare positioned within belts 117 to ensure proper traction as in the caseof rollers 74. Gates 123 are provided for each of the trays in upper bin53, individual solenoids 37 being provided to operate each gate 123 inthe same manner as described for gates 76 of lower bin 55. A suitablelight and phototransistor combination 125, 127 is provided in bin 53.

As will appear, the system operator may elect to use or not use sorter32 and/or document handler ,15. Where sorter 32 is not used, copies arestacked in processor tray 35. Where sorter 32 is used, the operator mayprogram the system 10 to provide either stacked or collated copy outputby actuating the selector S1 or S2, respectively, on control panel 6.Where it is desired to use the document handler 15, either alone or incombination with sorter 32, selector S3 or S4 is actuated, selector S3programming document handler 15 for automatic operation, selector S4 forsingle document feed. By depressing suitable ones of the switch buttonS5 the number of copies desired for each document is selected.

Whenever sorter selector S1 or S2 is actuated, the sorter logic 301(FIG. 4) interrogates sensors 303 and 305 to determine whether or notcopies, normally from a previous job, are in any of the trays 59 of bins53, 55. On a signal from either sensor 303 or 305, logic 301 precludesinput of copies to the bin 53, 55 affected. This is done by switchingdeflector 135 to the appropriate position. Should both sorter bins 53,55 have copies therewithin, the joint signals to logic 311 precludesoperation of the system 10 until such time as one or both of the bins53, 55 are cleared.

Sensors 303, 305, which are suitable phototransistors similar to sensorsand 127 described earlier, are located in lower and upper sorter bins 55and 53, respectively (FIG. 3). Suitable lamps 306, 307 are providedtherefor. Illumination from the lamps 306, 307 will be sensed by sensors303 and 305 when no sheet material is present in the sorter trays. Ifeither or both of the bins are empty, the signal from the sorter logic301 enables operation of processor. 11.

Print selector S6 controls start up of the printer system 10. Whereeither of selectors S3 or S4 is actuated, document handler 15 will feedthe first document from tray 17 to platen 12 of processor 11. With thefirst document in position, the signal from the document handler logic313 enables processor 11 to start copying, the resulting copies beingdeposited in either tray 35 of processor 11 or in sorter 32 if one ofthe sorter selectors S1 or S2 has been actuated.

When sorter 32 is used, where both bins 53, 55 are empty, deflector isin the position shown in FIG. 3. Copies are therefore routed into lowerbin 55 for stacking in trays 59 thereof, starting with tray 59.

In processor 11, an exposure counter 309 counts flashes of flash lamps18. It should be understood that the exposure counter could be used witha scan type exposure system as well.

It will be appreciated that phototransistors 80, 127 count the copiesentering the trays, the signals from one of phototransistors 80, 127being fed via OR circuit 302 to copy counter 415 which may comprise anysuit able counting device and which in cooperation with logic 310controls the position of tray deflectors 76, 123 as will appear. Inaddition, logic 301 controls starting and stopping of the individualsorter bin motors 153, 167, as well as the position of bin deflector135.

The signal output of copy counter 415 controls selectively throughsorter logic 310 the appropriate solenoid matrix circuits 427, 429 forsorter bins 53, 55. Matrix circuits 427, 429 control operation of thebins deflector solenoids 37 to raise and lower the individual fingers76, 123, respectively. Sorter logic 301 includes a suitable comparisoncircuit (not shown) which serves to compare the number of copiesprogrammed with the number of copies delivered as recorded by copycounter 415.

Printer system may be programmed for a collated copy output withmultiple document feed by actuating selectors S2 and S3. During systemoperation in this mode, sorter logic 301 stops the solenoid matrixcircuit 327 or 329 for the sorter section 53 or 55 then in use from astarting position wherein the first copy produced is routed into thefirst sorter tray 59 through a series of steps equal to the number ofcopies programmed or the total tray capacity of the sorter bin,whichever is less, in accordance with the copy program. Whenever thetotal number of copies pro grammed or the sorter tray capacity isreached by processor 11, the signal from counter 309 to processor logic311 stops the processor 11 while actuating document handler 15 to removethe document on platen 12 and bring up the next succeeding document.Following this, operation of processor 11 resumes.

In the meantime, as the last copy of the document previously on platen12 is deposited in the appropriate sorter tray, the signal from copycounter 415 causes sorter logic 301 to reset the deflector controlmatrix 427 or 429 for the sorter section then in use so that the firstcopy of the new document is directed into the first tray of the sorterbin.

The above process continues until the number of copies programmed isreached or until the last document in the document handler tray 17 isprocessed. Where the copy cycle is completed, a signal from counters309, 415 cycles out the reproduction system 10. However, where the lastdocument is copied but the program is not finished, the copy cycle isautomatically repeated. In this circumstance document handler functionsto refeed the first document from document tray 17 to platen 12 ofprocessor 11 in preparation for resumption of the copying process.

However, before processor 11 can commence operation, the signal inputfrom the appropriate detector 303 or 305 to sorter logic 301 reflectingthe presence of copies in the sorter bin just used, is responded to bysorter logic 301 which actuates deflector 135 to route the next batch ofcopies into the other empty sorter bin. The copy cycle thencontinues,'the copies generated by processor 11 being deposited in thetrays of the other sorter bin until either the program is completed, atwhich point the system cycles out, or the copy capacity of the bin thenin use is reached. in this latter case, following copying of the lastdocument, the document handler 15 again recycles the documents to bringthe first document into position on platen 12. At this point, signalinput from the detector 303 or 305 of the sorter secton last used willbe responded to by the sorter logic 301 which will switch deflector gate135 so as to route the next batch of copies into the other sortersection if that sorter section is empty. If the other sorter section hasnot been cleared of copies, and no other empty sorter section isavailable, the signals from both detectors 303, 305 to sorter logic 301inhibits further operation of the printer system 10 until such time asat least one of the sorter bins is empty.

It is understood that the reproduction system 10 may be operated in astack mode wherein the copies of each document produced by processor 11are stacked together in the various trays of sorter 32 starting with thefirst tray 59 of whichever bin 53 or 55 is in use. In this mode ofoperation one document at a time is positioned on platen 12, eitherautomatically by document handler 15 or manually by the operator, thelatter through the expediency of raising to document transport assembly141 and cover 9 to expose platen 12, placing the document thereon, andthen reclosing the transport and cover. It is understood that processorlogic control 311 is programmed for the number of copies to be made byactuating appropriate ones of the switches S5. At the same time,selector S1 :is actuated to set the sorter logic 301 to stack mode andselector S4 is actuated to set document handler logic 313 to single feedmode if document handler 15 is to be used.

In this mode of operation, when the total number of copies programmedfor the document being copied is reached, as indicated by counter 309,processor 11 cycles out and the document on platen 12 is removed bydocument handler 15. When the last copy therefor enters the first tray59 of the sorter bin 53 or 55 in use, the signal from copy counter 415to sorter logic 301 actuates the appropriate matrix circuit 427, 429 todepress the finger for the next succeeding sorter tray. The system isaccordingly ready to process the next document in tray 17. Processor 11may then be restarted to copy the second document in accordance with thepreviously established program.

The aforedescribed process continues until all the original documentshave been copied, the copies of each document being stacked insuccessive ones of the sorter trays. If, during the program, copies arestacked in the last tray of the bin being used, the signal from theappropriate bin detector 303, 305 to logic 301 switches bin deflector tothereafter direct copies into the other empty bin.

As will be understood, the sorter trays of sorter 32 have a limitedsheet storage capacity. To protect against overfilling of an individualsorter tray, a suitable counter circuit 500 is provided, circuit 500serving to identify the copy storage capacity of the individual sortertrays 59. Circuit 500, which may be preset at the factory for apredetermined number of copy sheets, may include suitable adjustingmeans (not shown) to enable the setting thereof to be changed in thefield to accommodate different types or weights of paper.

The output of circuit 500 is fed to a suitable comparator circuit 501having a second input from copy counter 415. The output of comparatorcircuit 501 is fed to sorter logic 301 controlling bin matrixes 427,429.

Enabling of circuit 500 may be controlled by sorter logic 301 inresponse to actuation of sorter stack selector S1. Circuit 500 is notnormally required when sorter collating selector S2 is actuated wherethe capacity of document handler 15 does not exceed the copy capacity ofthe individual sorter trays 59. In this circumstance, as will beunderstood, the number of copies made when collating cannot exceed thecopy capacity of the individual sorter trays. Where, however, thedocument handler 15 can handle a number of documents in excess of thecapacity of the individual sorter trays, counter circuit 500 may bearranged to be enabled whenever sorter 32 is used.

During operation of reproduction system 10 in the stacking mode,effected by actuating selector S1, with or without actuation of selectorS4 depending on whether or not it is desired to feed the documentsautomatically by document handler 15 or manually through the expediencyof raising platen cover 9 and transport 14, when the number of copiesfed to the tray in use equals the predetermined tray capacity asdetermined by circuit 500, comparison circuit 501 is triggered. Theother signal from circuit 501 to logic circuit 301 actuates the matrixcircuit 427, 429 for the sorter bin 53 or 55 in use to release thefinger 76, 123 for the tray then in use and depress the finger for thenext sorter tray. Succeeding copies of the program are therefore routedinto the next sorter tray. If the capacity of the next tray isinsufficient, circuit 500 will respond again when the capacity of thetray is reached to cause logic 301 to step to the next sorter tray, andso forth and so on until the program is completed.

On completion of the copy program for the document then on platen 12,the signal from copy counter 415 to sorter logic 301 switches to thenext succeeding empty sorter tray or bin as the case may be and copiesof the next document enter the next succeeding tray or bin.

it will be understood the counter circuit 500 and comparison circuit 501may be replaced by individual sheet detectors in each of the sortertrays adapted to generate a signal whenever the number of sheets in thetray reach a predetermined number. In this circumstance the signal wouldbe fed directly to sorter logic 301.

While the invention has been described with reference to the structuredisclosed, it is not confined to the details set forth, but is intendedto cover such modifications or changes as may come within the scope ofthe following claims.

What is claimed is:

1. In a reproduction system for producing copies of documents andarranging said copies selectively in either stacked or collatedrelationship, the combination of:

a processor for producing said copies from original documents; a sorterfor arranging said copies in either of said stacked or collatedrelationships, said sorter having plural copy receiving trays arrangedin at least two distinct sections; and,

control means adapted to prevent the start of the reproduction system inthe absence of an empty section in said sorter, said control means beingadapted to allow the start of the reproduction system when at least oneof said sections is empty and direct the copies produced to said emptysection, said control means being adapted when both of said sortersections are empty to route copies to a predetermined one of saidsections.

2. In a reproduction system the combination of:

a processor for making copies of original documents;

a sorter for sorting said copies into desired orientation, said sorterhaving at-least two distinct sections, each section containing a seriesof copy receiving trays arranged in procession starting with a firsttray;

programming means for selectively programming said system so that saidprocessor and sorter cooperate to provide a collated set of copies ineach of the sorter trays used, with the first said copy sets in thefirst tray of one of said sections or copies of each document inindividual ones of said sorter trays with copies of the first documentpage in the first tray of one of said sections; and,

control means including copy sensing means adapted to sense the presenceof copies in each section of said sorter, said control means beingadapted to prevent initiation of a copy cycle when copies are present ineach section, and allow initiation of a copy cycle when at least onesection is empty, said control means causing the copies produced to bedirected to said empty section.

3. A reproduction system according to claim 2 wherein said control meansis adapted to direct copies into a predetermined secton of said sorterwhen all said sections are empty.

1. In a reproduction system for producing copies of documents andarranging said copies selectively in either stacked or collatedrelationship, the combination of: a processor for producing said copiesfrom original documents; a sorter for arranging said copies in either ofsaid stacked or collated relationships, said sorter having plural copyreceiving trays arranged in at least two distinct sections; and, controlmeans adapted to prevent the start of the reproduction system in theabsence of an empty section in said sorter, said control means beingadapted to allow the start of the Reproduction system when at least oneof said sections is empty and direct the copies produced to said emptysection, said control means being adapted when both of said sortersections are empty to route copies to a predetermined one of saidsections.
 2. In a reproduction system the combination of: a processorfor making copies of original documents; a sorter for sorting saidcopies into desired orientation, said sorter having at least twodistinct sections, each section containing a series of copy receivingtrays arranged in procession starting with a first tray; programmingmeans for selectively programming said system so that said processor andsorter cooperate to provide a collated set of copies in each of thesorter trays used, with the first said copy sets in the first tray ofone of said sections or copies of each document in individual ones ofsaid sorter trays with copies of the first document page in the firsttray of one of said sections; and, control means including copy sensingmeans adapted to sense the presence of copies in each section of saidsorter, said control means being adapted to prevent initiation of a copycycle when copies are present in each section, and allow initiation of acopy cycle when at least one section is empty, said control meanscausing the copies produced to be directed to said empty section.
 3. Areproduction system according to claim 2 wherein said control means isadapted to direct copies into a predetermined secton of said sorter whenall said sections are empty.